DC/DC converter

ABSTRACT

The present invention relates to a DC/DC converter ( 1 ) with primary side ( 11 ) consisting of a resonant converter, which DC/DC converter ( 1 ) comprises a first and a second transformer (T 1 , T 2 ), connected in series on the primary side ( 11 ) and on the secondary side ( 12 ) of the DC/DC converter. The secondary side ( 12 ) comprises an autotransformer (Tcd) consisting of a first and a second winding (Tcda, Tcdb) connected to a common center tap (Tcdc), where the first winding (Tcda) of the autotransformer (Tcd) is connected to the secondary winding (T 1   b ) of the first transformer (T 1 ), forming a first output connection point (P 1 ), the second winding (Tcdb) of the autotransformer (Tcd) is connected to the secondary winding (T 2   b ) of the second transformer (T 2 ), forming a second output connection point (P 2 ).

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.13/150,997, filed on Jun. 1, 2011, which is a continuation ofInternational Application No. PCT/CN2010/072439, filed on May 4, 2010,which is hereby incorporated by reference in its entirety.

FIELD OF INVENTION

The present invention relates to a DC/DC converter with primary sideconsisting of a resonant converter, which converter comprises at leastone transformer, and a converter system comprising at least twoinventive DC/DC converters.

DESCRIPTION OF BACKGROUND ART

The developing trend of the AC/DC, DC/DC converters is high efficiencyand high power density. Through the Resonant AC/DC, DC/DC Converters itis easier to achieve high efficiency due to its feature ofsoft-switching.

However, there are still certain existing drawbacks regarding theResonant Converters, e.g., the high AC-current of the output filterresulting in the high power losses and the large volume of the outputfilter. Furthermore, the center tapped transformer is less efficient andmore difficult to optimize due to the passive winding.

The most widely used Series Resonant Converter found in the industry isthe LLC-Resonant Converter, due to its availability to achieve highefficiency. This topology has been described in different publications,an example of this is the publication “Steady-state analysis of the LLCConverter”, IEEE 16th Annual Applied Power Electronics Conference,Volume: 2, pp: 728-725, March 2001 by James F Lazar, Robert Martinelli.

The current protection of the circuit disclosed in this publication hasbeen analyzed and the solution using splitting resonant capacitors andclamping diodes has been presented in the publication “Over CurrentProtection Methods of the LLC Resonant Converter”, IEEE 18th AnnualApplied Power Electronics Conference, Volume: 2, pp: 605-609, February2003, by Bo Yang, Fred Lee, Matthew Concannon.

For low voltage/high current applications and for high powerapplications in particular, it has been known to place two or moreResonant Converters in series and/or parallel, as described in thepublication “Phase-Staggering Control of a Series-Resonant DC-DCConverter with Paralleled Power Modules”, IEEE Transactions on PowerElectronics, Volume: 3, pp: 164-173, April 1988, by Ben Klaassens, W. L.F. H. A. Moize de Chateleux, M. P. N. Van Wesenbeeck.

The present invention uses the concept of the so called Three-StateSwitching Cell (TSSC) in a novel manner, however, the Three-StateSwitching Cell is part of the prior art of the present invention and itis described in publication “Generation of a family of non-isolatedDC-DC PWM converters using a three-state switching cell”, IEEE 31thAnnual Power Electronics Specialists Conference, Volume: 2, pp: 858-863,18-23 June, 2000, by G. V. T. Bascopé and Ivo Barbi.

SUMMARY OF THE PRESENT INVENTION Technical Problems

It is a general problem regarding two stage rectifiers to meetrequirements of efficiency in the DC/DC Converter.

It is also a problem to improve the thermal distribution in a DC/DCconverter.

Yet another problem regarding DC/DC converters is to meet the demand ofincreasing DC power.

It is also a problem to reduce the AC ripple on the output capacitors,and to do this without having to increase the number of neededcapacitors.

Another problem is to reduce the voltage stress when the input voltageis high, and to reduce the current stress.

Achieving high efficiency in the topological circuits existing in themarket today is only possible with increased number of semiconductors,magnetic components and amount of copper within the possibilities of thestate of the art of power electronics. This will however increase thepower density.

If a converter is going to be optimized for high density, the efficiencywill definitely be lower.

The choice for optimization in the existing solutions according to thebackground art is either efficiency or high density, but never both.

Solution

With the purpose of providing a novel topological circuit speciallysuitable for high power, high efficiency and high density applicationsin the art of power electronics and of solving one or more of the aboveindicated problems, and from the standpoint of the above indicated fieldof invention, the present invention teaches that the secondary side ofthe DC/DC converter comprises an autotransformer consisting of a firstand a second winding connected to a common center tap, whichautotransformer is adapted to act as a current doubler.

One embodiment of the present invention teaches that the at least onetransformer can be a first and a second transformer (T1, T2), connectedin series on the primary side and on the secondary side of said DC/DCconverter.

The first winding of the autotransformer is connected to the secondarywinding of the first transformer, forming a first output connectionpoint, the second winding of said autotransformer is connected to thesecondary winding of the second transformer, forming a second outputconnection point, and the center tap of the autotransformer is connectedto the positive output of the secondary side.

The secondary side also comprises a first and a second rectifyingswitching device, which first rectifying switching device is connectedbetween the first output connection point and the negative output of thesecondary side, and which second rectifying switching device isconnected between the second output connection point and the negativeoutput of the secondary side.

Adding the autotransformer on the secondary side, will allow the removalof the centre tap of the transformer and will also reduce the current onthe secondary side to half the original value.

Removing the centre tap of the transformer is not only increasing theefficiency, but also simplifying the layout of the secondary side, andthereby greatly reducing the increased complexity when a number ofconverters are connected in parallel.

Another important feature in the invention is that the transformer onthe converter is divided in order to reduce the voltage and currentstress. Two transformers are connected in series on the primary sidereducing the voltage stress. On the secondary side, the windings arealso connected in series in order to achieve the required output voltagewithout changing the turns-ratio of the transformer as is required inthe current doublers of the state of the art.

Furthermore, the manufacturing process of the transformers is improvedas well.

The present invention teaches that the first and second rectifyingswitching device can either consist of a first and second transistor, ora first and second rectifying diode. If transistors are used then it ispreferred if that the first and second transistor is adapted tosynchronous rectification.

Using transistors and synchronous rectification provides a possibilityto meet the requirements of increased efficiency. However, thecomplexity of this is increasing if a number of converters areparalleled, in which case it could be preferred to use rectifyingdiodes.

The present invention teaches that the primary side if the inventiveDC/DC converter may consist of a resonant converter, which resonantconverter can be an LLC resonant converter that can work in both Buckand Boost mode in order to achieve wide input and output voltages.

As can be seen in the description of the secondary side, this sidefollows the principles of a Three-State Switching Cell (TSSC).

The present invention also relates to a DC/DC converter system, whichsystem comprises at least two inventive DC/DC converters. These DC/DCconverters can be connected in parallel or in series. It is alsopossible to connect the DC/DC converters in an inventive DC/DC convertersystem in series on the primary side and in parallel on the secondaryside, or in parallel on the primary side and in series on the secondaryside.

It is proposed that when the system comprises two DC/DC converters, itis possible that the DC/DC converters are interleaved with 90 degreesphase shift. The system can then be adapted to be powered from an inputsource, and to receive a three-level voltage (P, M, N) from the inputpower source. One such input from a source can be a power factorcorrection regulator, in which case it is proposed that the systemcomprises two input capacitors through which said input source isconnected.

Paralleling of converters is a way to solve the demand of increasingDC-power, and interleaving them with phase shift will reduce theAC-current ripple on the output capacitors which will reduce the numberof capacitors needed.

A series connection on the primary side can be used to reduce thevoltage stress when the input voltage is high. For the secondary side,it is proposed that the outputs of the converters are put in parallel inorder to reduce the current stress.

The reliability of the converter is increased due to the reduction ofthe current stress on the winding of the transformers and the improvedthermal distribution in the unit.

It is proposed that the output filter of the secondary side consist ofan output capacitor and an output EMI filter.

ADVANTAGES

The advantages of a converter and a system according to the presentinvention are that a very high efficiency and high power density can beachieved.

The invention provides simplified and more efficient transformers, asthe passive winding has been removed, due to the function of operationof the 3SSC.

Increased reliability is provided due to a better thermal distribution.

The simplified and more efficient layout on the secondary side alsoreduces the losses.

Interleaving two or more converters reduces the number of capacitorsneeded for the output filter when phase-shifting control is used.

Splitting the transformers on each converter provides a reduced voltageand current stress and consequently reduces the losses.

The high density is provided due to the reduction of the number ofoutput capacitors and reduced total size of the transformer (s) due tothe characteristics of the topological circuit.

The invention also provides a simplified transformer manufacturing andPCB assembly.

A circuit according to the present invention can be implemented for anypower level as there is no inherent limitation in the topologicalcircuit.

A circuit according to the present invention can also be extended forany number of converters and different kind of connections(series/parallel) or for a single DC/DC Resonant Converter.

BRIEF DESCRIPTION OF THE DRAWINGS

A DC/DC converter and a DC/DC converter system according to the presentinvention will now be described in detail with reference to theaccompanying drawings, in which:

FIG. 1 is a schematic and simplified illustration of a first proposedembodiment of a single DC/DC converter,

FIG. 2 is a schematic and simplified illustration of a second proposedembodiment of a single DC/DC converter,

FIG. 3 is a schematic and simplified illustration of a first proposedembodiment of a DC/DC converter system with two converters connected inseries,

FIG. 4 is a schematic and simplified illustration of a second proposedembodiment of a DC/DC converter system with two converters connected inparallel,

FIG. 5 is a schematic and simplified illustration of a third proposedembodiment of a DC/DC converter system with two converters connected inparallel on the primary side and in series on the secondary side, and

FIG. 6 is a schematic and simplified illustration of a fourth proposedembodiment of a DC/DC converter system with two converters connected inseries on the primary side and in parallel on the secondary side.

DESCRIPTION OF EMBODIMENTS AS PRESENTLY PREFERRED

The present invention will now be described with reference to FIG. 1showing a DC/DC converter 1 with primary side 11 consisting of aresonant converter, the DC/DC converter 1 comprising at least onetransformer, in the following embodiments exemplified by a first and asecond transformer T1, T2, connected in series on the primary side 11and on the secondary side 12 of said DC/DC converter.

The figure shows schematically the primary winding T1 a of the firsttransformer T1 and the primary winding T2 a of the second transformer T2on the first side 11 of the converter 1. It also shows the secondarywinding T1 b of the first transformer T1 and the secondary winding T2 bof the second transformer T2 on the second side 12 of the converter 1.

The secondary side 12 of said DC/DC converter 1 comprises anautotransformer Tcd consisting of a first and a second winding Tcda,Tcdb connected to a common centre tap Tcdc. The autotransformer Tcd isadapted to act as a current doubler.

The first winding Tcda of the autotransformer Tcd is connected to thesecondary winding T1 b of the first transformer T1, forming a firstoutput connection point P1, the second winding Tcdb of theautotransformer Tcd is connected to the secondary winding T2 b of thesecond transformer T2, forming a second output connection point P2, andthe center tap Tcdc of the autotransformer Tcd is connected to thepositive output 21 of the secondary side 12.

The secondary side 12 also comprises a first and a second rectifyingswitching device S1, S2, where the first rectifying switching device S1is connected between the first output connection point P1 and thenegative output 22 of the secondary side 12, and the second rectifyingswitching device S2 is connected between the second output connectionpoint P2 and the negative output 22 of the secondary side 12.

The rectifying switching devices S1, S2 can be realised throughdifferent means of switching or controlling the currents from the firstand second connection point P1 and P2 to the negative output 22 of thesecondary side 12. In FIG. 1 an embodiment of the present invention isillustrated where the first and second rectifying switching device S1,S2 is consisting of a first and second transistor, and it is proposedthat that the first and second transistor is adapted to synchronousrectification.

FIG. 2, only showing the secondary side 12 of the DC/DC converter 1,illustrates an alternative embodiment of the present invention where thefirst and second rectifying switching device S1′, S2′ is consisting of afirst and second rectifying diode.

With renewed reference to FIG. 1, an embodiment of an inventiveconverter 1 is shown where the primary side 11 consists of a resonantconverter, in this case an LLC resonant converter that can work in bothBuck and Boost mode in order to achieve wide input and output voltages.

The figure shows an example where the first side of the converter 11 isa symmetrical half bridge converter with a first and second clampingdiode Dc1, Dc2. As an illustrating example, the first side 11 of theconverter 1 comprises a first and a second main switch S11, S12, in thefigure exemplified as main transistors, a resonant inductor Lr, and afirst and second resonant capacitor Cr1, Cr2 in parallel with the firstand second clamping diode Dc1 and Dc2 respectively.

It can be seen that the secondary side 12 of the inventive converter 1consist of a Three-State Switching Cell (TSSC).

The present invention also relates to a DC/DC converter systemcomprising at least two DC/DC converters according to the presentinvention. It shall be understood that the number of used converters isdecided by the implementation of the invention, and that the inventionis not limited to any number of converters. For the sake of simplicity,two converters are shown in the embodiments illustrated in thedescription and the figures, and FIGS. 3 to 6 shows differentexemplifying embodiments of how two DC/DC converters 31, 32 can bearranged into a DC/DC converter system 3.

FIG. 3 shows that the converters 31, 32 are connected in parallel.

FIG. 4 shows that the converters 31, 32 are connected in series.

FIG. 5 shows that the converters 31, 32 are connected in parallel on theprimary side 11 and in series on the secondary side 12.

FIG. 6 shows that the converters 31, 32 are connected in series on theprimary side 11 and in parallel on the secondary side 12.

FIG. 6 also shows an embodiment where the system 3 comprises two DC/DCconverters 31, 32, which converters are interleaved with 90 degreesphase shift.

The system 3 is adapted to be powered from an input source 4, and toreceive a three-level voltage P, M, N from the input power source 4.Such input power source 4 can for instance be a power factor correctionregulator. In the figure it is shown that the system 3 comprises a firstand a second input capacitor Ci1, Ci2 through which the input powersource 4 is connected.

Regardless of implementation, and whether there is a single DC/DCconverter or a system with at least two DC/DC converters, it is proposedthat an output filter of the secondary side consist of an outputcapacitor and an output electromagnetic interference (EMI) filter. Thisis shown in FIG. 1 as the output capacitor Cf and the output filter 23,and in FIG. 6 as the output capacitor Cf and an output filter 33.

It will be understood that the invention is not restricted to theaforedescribed and illustrated exemplifying embodiments thereof and thatmodifications can be made within the scope of the inventive concept asdefined in the accompanying Claims.

1. A direct current to direct current (DC/DC) converter comprising: aprimary side: a first transformer and a second transformer, whereinrespective primaries of the first transformer and the second transformerare connected in series on the primary side of the DC/DC converter andrespective secondary's of the first transformer and the secondtransformer are connected in series on a secondary side of said DC/DCconverter, wherein the secondary side of the DC/DC converter comprises:an autotransformer that includes a first winding and a second winding,wherein respective first ends of the first winding and the secondwinding are connected to form a common center tap, configured as acurrent doubler, wherein a second end of the first winding of theautotransformer is connected to the secondary winding of the firsttransformer, forming a first output connection point, wherein a secondend of the second winding of the autotransformer is connected to thesecondary winding of the second transformer, forming a second outputconnection point, wherein the center tap of the autotransformer isconnected to a positive output of the secondary side of the DC/DCconverter, wherein the secondary side of the DC/DC converter comprises afirst rectifying switch and a second rectifying switching device,wherein the first rectifying switching device is connected between saidfirst output connection point and a negative output of the secondaryside of the DC/DC converter, and wherein the second rectifying switchingdevice is connected between the second output connection point and thenegative output of said secondary side of the DC/DC converter.
 2. TheDC/DC converter according to claim 1, wherein said first rectifyingswitching device and second rectifying switching device correspondrespectively to a first transistor and a second transistor, wherein thefirst transistor and second transistor are configured to performsynchronous rectification.
 3. The DC/DC converter according to claim 1,wherein said first rectifying switching device and the second rectifyingswitching device correspond respectively to a first rectifying diode anda second rectifying diode.
 4. The DC/DC converter according to claim 1,wherein said primary side of the DC/DC converter includes a resonantconverter.
 5. The DC/DC converter according to claim 4, wherein saidresonant converter is an LLC resonant converter that can work in bothBuck and Boost mode in order to achieve wide input and output voltages.6. The DC/DC converter according to claim 1, wherein said secondary sideconsist of a Three-State Switching Cell (TSSC).
 7. The DC/DC converteraccording to claim 1, wherein the output filter of the secondary side ofthe DC/DC converter includes an output capacitor and an output EMIfilter.
 8. A direct current to direct current (DC/DC) converter systemcomprising: a first DC/DC converter and a second DC/DC converter,wherein each DC/DC converter includes: a primary side includes aresonant converter, a first transformer and a second transformer,wherein respective primaries of the first transformer and the secondtransfer are connected in series on the primary side of the DC/DCconverter and respective secondary's of the first transformer and thesecond transformer are connected in series on a secondary side of saidDC/DC converter, wherein the secondary side of the DC/DC convertercomprises: an autotransformer that includes a first winding and a secondwinding, wherein respective first ends of the first winding and thesecond winding are connected to a common center tap, configured as acurrent doubler, wherein a second end of the first winding of theautotransformer is connected to the secondary winding of the firsttransformer, forming a first output connection point, wherein a secondend of the second winding of said autotransformer is connected to thesecondary winding of the second transformer, forming a second outputconnection point, wherein the center tap of the autotransformer isconnected to a positive output of the secondary side of the DC/DCconverter, wherein the secondary side of the DC/DC converter comprises afirst rectifying switching device and a second rectifying switchingdevice, wherein the first rectifying switching device is connectedbetween the first output connection point and a negative output of saidsecondary side of the DC/DC converter, and wherein the second rectifyingswitching device is connected between the second output connection pointand the negative output of said secondary side of the DC/DC converter.9. The DC/DC converter system according to claim 8, wherein the firstDC/DC converter and the second DC/DC converter are connected inparallel.
 10. The DC/DC converter system according to claim 8, whereinthe first DC/DC converter and the second DC/DC converter are connectedin series.
 11. The DC/DC converter system according to claim 8, whereinthe first DC/DC converter and the second DC/DC converter are connectedin parallel on respective primary sides of the first DC/DC converter andthe second DC/DC converter and in series on respective secondary sidesof the first DC/DC converter and the second DC/DC converter.
 12. TheDC/DC converter system according to claim 8, wherein the first DC/DCconverter and the second DC/DC converter are connected in series onrespective primary sides of the first DC/DC converter and the secondDC/DC converter and in parallel on respective secondary sides of thefirst DC/DC converter and the second DC/DC converter.
 13. The DC/DCconverter system according to claim 12, wherein the first DC/DCconverter and the second DC/DC converter are interleaved with 90 degreesphase shift.
 14. The DC/DC converter system according to claim 13,wherein the DC/DC converter system is configured to be powered from athree-level voltage power source.
 15. The DC/DC converter systemaccording to claim 13, wherein the DC/DC converter system is configuredto receive power from a power source with that includes a power factorcorrection regulator, wherein each DC/DC converter further comprises twoinput capacitors through which said power source is connected.
 16. TheDC/DC converter system according to claim 14, wherein the DC/DCconverter system is configured to receive power from a power source thatincludes a power factor correction regulator, wherein each DC/DCconverter system further comprises two input capacitors through whichsaid input source is connected.
 17. The DC/DC converter system accordingto claim 8, wherein the output filter of the secondary side of the DC/DCconveter includes an output capacitor and an output EMI filter.
 18. TheDC/DC converter system according to claim 8, wherein the secondary sideof each DC/DC converter includes a three-state switching cell.